Multi-ply aluminum bonded cookware

Abstract

Cookware, such as a stock pot, fry pan, sauté pan, griddle, or grill, comprising a basic three-ply bonded composite includes two layers of an aluminum alloy, such as 3003 or the like, bonded on opposed sides to a core layer of higher purity aluminum, such as 1050, 1100, 1145, or the like, to define a three-ply composite cookware product. One or more additional layers of higher purity aluminum are bonded intermediate one or more additional layers of aluminum alloy to form five-ply, or seven-ply, or more, bonded composite cookware products. The exterior layers of aluminum alloy may also include a non-stick coating and/or an anodized coating.

What is claimed is: 
     
       1. Cookware of a multi-layer bonded composite comprising first and second layers of an aluminum alloy directly bonded to opposed sides of a first core layer of a higher purity aluminum. 
     
     
       2. The cookware of  claim 1 , including a non-stick coating applied to a cook surface of a first of the two layers of aluminum alloy and an anodized coating applied to an exterior surface of at least a second of the two layers of aluminum alloy. 
     
     
       3. The cookware of  claim 1 , wherein exterior surfaces of the first and second aluminum alloy layers have an anodized layer applied thereto. 
     
     
       4. The cookware of  claim 3 , wherein the anodized layer on the first aluminum layer has a non-stick layer applied thereto, defining a cook surface of the cookware. 
     
     
       5. The cookware of  claim 1 , including a second core layer of higher purity aluminum directly bonded to the second of the aluminum alloy layers and including a third layer of aluminum alloy directly bonded to the second core layer of higher purity aluminum. 
     
     
       6. The cookware of  claim 5 , including a non-stick coating applied to a cook surface of the first of the layers of aluminum alloy and an anodized coating applied to an exterior surface of at least the third layer of aluminum alloy. 
     
     
       7. The cookware of  claim 5 , further including a third core layer of higher purity aluminum directly bonded to the third aluminum alloy layer and a fourth aluminum alloy layer directly bonded to the third core layer of higher purity aluminum. 
     
     
       8. The cookware of  claim 7 , including a non-stick coating applied to a cook surface of the first aluminum alloy layer and an anodized coating applied to an exterior surface of at least the fourth aluminum alloy layer. 
     
     
       9. The cookware of  claim 1 , defining a three-ply bonded composite product in the form of a stock pot, fry pan, sauté pan, griddle, or grill. 
     
     
       10. The cookware of  claim 2 , defining a three-ply bonded composite product in the form of a stock pot, fry pan, sauté pan, griddle, or grill. 
     
     
       11. The cookware of  claim 5 , defining a five-ply bonded composite product in the form of a stock pot, fry pan, sauté pan, griddle, or grill. 
     
     
       12. The cookware of  claim 6 , defining a five-ply composite cookware product in the form of a stock pot, fry pan, sauté pan, griddle, or grill. 
     
     
       13. The cookware of  claim 7 , defining a seven-ply composite cookware product in the form of a stock pot, fry pan, sauté pan, griddle, or grill. 
     
     
       14. The cookware of  claim 8 , defining a seven-ply composite cookware product in the form of a stock pot, fry pan, sauté pan, griddle, or grill. 
     
     
       15. The cookware of  claim 1 , wherein the first and second aluminum alloy layers are one of 3003, 3004 or like aluminum alloy and the core layer has an aluminum content of at least 99% by weight. 
     
     
       16. The cookware of  claim 5 , wherein the first and second aluminum alloy layers are one of 3003 or 3004 aluminum alloy and the core layer is one of 1050, 1100, or 1145aluminum. 
     
     
       17. The cookware of  claim 7 , wherein the first and second aluminum alloy layers are one of 3003 or 3004 aluminum alloy and the core layer is one of 1050, 1100, or 1145 aluminum. 
     
     
       18. A method for manufacturing cookware comprising the steps of:
 providing a bonded composite comprising at least three layers of material including a core layer of a high purity aluminum, and two layers of an aluminum alloy wherein each layer of the aluminum alloy is bonded to the core layer of high purity aluminum; and 
 forming the bonded composite into a cookware shape. 
 
     
     
       19. The method of  claim 18  including the steps of:
 applying a non-stick coating to one of the aluminum alloy layers to define a cooking surface; and 
 applying an anodized coating to the other of the aluminum alloy layers to define an outer surface of the cookware. 
 
     
     
       20. The cookware of  claim 2  wherein the anodized coating is applied to both the first and second layers of aluminum alloy and the non-stick coating is applied to the anodized coating on the first layer of aluminum to define a cook surface of the cookware.